Thermoformed blister package

ABSTRACT

A blister package ( 10 ) and method for manufacturing the blister package include an upper wall member ( 14 ) (e.g., front panel), a lower wall member ( 16 ) (e.g., backer) and a printing ( 20 ) (e.g., print, decoration, advertising), where the upper wall member is formed to effectively hold an article ( 12 ) (e.g., toothbrush, razor) preferably by accommodating specific geometry of the article. The lower wall member is preferably formed (e.g., molded, thermoformed) after printing from a flat sheet of material (e.g., plastic) to resemble a cylindrical or cone based final shape linearly along or parallel to the lower wall member&#39;s longitudinal axis ( 46 ). The printing is applied to the flat sheet of material without distortion and appears on the final shaped lower wall member without the appearance of distortion.

FIELD OF THE INVENTION

The present invention relates to blister packages having a three-dimensional backer with printing on the backer.

BACKGROUND OF THE INVENTION

Various blister packages are known in the prior art for holding and displaying articles of merchandise, such as toothbrushes or razors. These blister packages are typically thermoformed plastic and include a backer or base member and a front panel closure member coupled to each other by a seal or weld. While the front panel is typically molded into a three-dimensional shape resembling the contours of the article held within, the backer is formed in either two dimensions or shaped into three dimensions. See, for example, U.S. Pat. Nos. 6,276,529 and 6,409,019, and United States Published Application U.S.2001/0032796 A1.

These blister packages often include printing for informational or advertising purposes. Typically, the printing is found on flat two-dimensional sections of the package where they are easily readable due to their appearance on the flat surface. See, for example, U.S. Pat. No. 6,571,953 and U.S. Application Publication U.S.2007/0051652 A1.

By way of example, U.S. Application Publication U.S.2009/0090643 A1 discloses a blister package for display of a toothbrush. The plastic blister package includes first and second plastic films 16, 20 that are pre-printed in a flat status before deep-drawing, with the printed area being later situated in a three-dimensionally molded portion of the blister package. The pre-printing is contoured or distorted prior to the molding to acquire the correct appearance after the deep-drawing process.

While the foregoing packages are generally suited for their intended purposes, they leave something to be desired from the standpoint of simplicity and preparing print or graphics for the printing on a flat sheet of plastic before the plastic is molded into a three-dimensional shape that noticeably distorts the graphic/printing design. Accordingly, a need exists for greater flexibility and efficiency for pre-printing during the manufacture of blister packages to achieve minimal distortion in the thee-dimensional final shape.

BRIEF SUMMARY OF THE INVENTION

In one embodiment there is a blister package for housing an article or merchandise, e.g. a toothbrush. The package comprising a front panel, a backer molded from a planar film to define a outline portion having a longitudinal axis and a printing applied to the planar film. The printing is applied to the planar plastic film having an appearance substantially free of distortion on the planar film. The outline portion is linear along the longitudinal axis. The front panel and backer are secured to each other to define a region for holding the article. The printing is legible on the backer irrespective of the distortion caused in molding the backer from the planar film.

In another embodiment there is a method for making a blister package for housing an article. The method for making a blister package for housing an article comprises providing a front panel; applying a printing to a planar film, the printing having an appearance free of distortion on the planar film; thermoforming the planar film into a backer to define a outline portion having a longitudinal axis with the outline portion linear along the longitudinal axis, the printing molded with the second planar film and maintaining a legible appearance regardless of distortion caused by the molding; placing the article into one of the front panel or the backer; and sealing the front panel and the backer together with the article in between the front panel and the backer.

In certain embodiments the outline portion is cone shaped.

In certain embodiments, the first three-dimensional thermoformed structure protrudes from the planar rim a first distance, and the second three-dimensional structure protrudes form the planar flange a second distance less than the first distance.

In certain embodiments the outline portion ahs a convex curve cross-section.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a top plan view of an exemplary embodiment of a blister package constructed in accordance with the invention and housing an article of merchandise;

FIG. 2 is a side elevation view of the package shown in FIG. 1;

FIG. 3 is a bottom plan view of the package shown in FIGS. 1 and 2;

FIG. 4 is an enlarged sectional view taken along line IV-IV of FIG. 1;

FIG. 5 is a bottom view of an exemplary planar film prior to being thermoformed into a cylindrical outline portion;

FIG. 6 is a bottom view of a cylindrical outline portion thermoformed from the planar film shown in FIG. 5; and

FIG. 7 is a perspective view of the package shown in FIGS. 1-3 housing the exemplary article of merchandise.

DETAILED DESCRIPTION OF THE INVENTION

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

Unless otherwise specified, all amounts, quantities, and geometric features expressed herein and elsewhere in the specification should be understood to include substantial approximations of the express term. For example, the term “planar” should be understood as including generally or approximately planar configurations.

While not being limited to a particular theory, the exemplary aspects of the invention include a blister package and method for manufacturing the blister package including an upper wall member (e.g., front panel), a lower wall member (e.g., backer) and a printing (e.g., print, decoration, advertising), where the upper wall member is formed to effectively hold an article (e.g., toothbrush, razor) preferably by accommodating specific geometry of the article. The lower wall member is preferably formed (e.g., molded, thermoformed) after printing from a flat sheet of material (e.g., plastic) to resemble a cylindrical or cone based final shape linearly along or parallel to the lower wall member's longitudinal axis. The printing is applied to the flat sheet of material without distortion and appears on the final shaped lower wall member without the appearance of distortion. This combination of the upper and lower wall members are secured together preferably by a three-dimensional seal or weld curve generally practiced as a two-dimensional seal or weld.

The embodiments improve the quality of the printing placed on the lower wall member or backer and give the backer a three-dimensional shape from non-distorted printing placed on the flat sheet in comparison to the known flat planar appearance. An advantage of the cylindrical/cone shaped backer is that the backer is not distorted to the same extent as the upper wall member. This provides the benefit that the printing need not be pre-distorted prior to final assembly of the blister package as known in the art at least in part due to the longitudinal linear shape of the assembled lower section. This benefit allows for better graphics/printed designs and flexibility. A further benefit of the three-dimensional backer is created by forming see-through windows on the backer that provide visual access to the back or side of the article (e.g., toothbrush heads) or other features of the article that traditionally are blocked from view.

The invention is further described in the following examples. The examples are merely illustrative and do not in any way limit the scope of the invention as described and claimed.

Referring now to the drawings wherein like reference numbers refer to like parts, there is shown at 10 in FIG. 1 an exemplary embodiment of a blister package constructed in accordance with the invention. The package 10 is arranged to hold an article of merchandise. In the exemplary embodiment shown, the item of merchandise is a toothbrush 12 (FIG. 7), but could be any product. The particular embodiment of the package 10 shown in FIG. 1 is a blister-type package. Alternatively, it can be in the form of a clam-shell type package. In either case, the package basically comprises a pair of wall members, herein referred to as a front panel 14 and a backer 16. The wall members are fixedly secured to each other to form an article receiving pocket 18 (FIG. 4) therebetween. The blister package 10 also includes a printing 20 (FIGS. 2, 3, 5, 6) on the backer 16.

The wall members are formed of any suitable material, e.g., a plastic or polymeric material, such as, but not limited to, polyvinyl chloride (PVC), polyethylene terephthalate (PET), etc., or any other material known for use in blister or clam-shell packaging. The material making up the wall members may comprise a combination of materials, including transparent, partially transparent, semi-transparent, opaque and and/or non-transparent materials and may be formed in any manner, such as thermoforming, injection or molding.

FIGS. 1-3 depict the blister package 10 in a top plane view, a side elevational view, and a bottom plane view, respectively. As can best be seen in FIG. 1, the front panel is an elongated member having a pair of long side edges 22 and 24 extending with the elongation and a pair of short end edges 26, 28 extending transversely to the elongation. The front panel 14 includes a first three-dimensional thermoformed structure 30 and a planar rim 32 extending about the periphery of the first three-dimensional thermoformed structure. The first three-dimensional thermoformed structure is molded from a first planar plastic film that forms the first wall member and protrudes from the planar rim 32 a distance D1 (FIG. 4) to define a hollow body as an article receiving portion 34. The article receiving portion 34 is a recess for receipt of the article of merchandise, and extends substantially the full length of the front panel 14, except for a top portion 36 adjacent the short end edge 26 that forms a header of the package 10. The top portion 36 is shown forming a hook 38 for hanging the package 10 from a display rack. The article receiving portion 34 can be of uniform width and depth along its entire length or can be profiled to the specific profile of the item of merchandise as can be seen in FIG. 7. In the exemplary embodiment shown, the article receiving portion 34 is profiled to conform to the profile of the toothbrush 12.

As can best be seen in FIGS. 1 and 2, the planar rim 32 extends outward about the entire periphery of the first three-dimensional thermoformed structure 30 to form its edges 22, 24, 26, 28. The planar rim 32 serves as the means for securing the front panel 14 to the backer 16. For example, the front panel 14 and backer 16 may be secured by a seal or weld as would be readily understood by a skilled artisan.

The second wall member which serves at the backer 16 of the package 10 includes a generally cylindrical or cone shaped member as a second three-dimensional thermoformed structure 40, and a planar flange 42 extending about the periphery of the second three-dimensional thermoformed structure that is of a corresponding size and shape to the planar rim 32. The second three-dimensional thermoformed structure 40 is molded from a second planar plastic film and protrudes from the planar flange 42 to define a cylindrical outline portion 44 having a longitudinal axis 46 with the cylindrical outline portion linear along the longitudinal axis (FIG. 2).

Thus, as can best be seen in FIGS. 2 and 3, the backer is an elongated member including a pair of long side edges 48, 50 extending generally parallel to the axis 46, and a pair of short side edges 52, 54 extending transverse to the axis 46. While not being limited to a particular theory, FIG. 2 demonstrates that the longitudinal axis 46 is offset from and not limited to a parallel alignment with the plane of the planar flange 42. For example, when the longitudinal axis 46 is not in parallel with the planar flange plane, the second three-dimensional thermoformed structure may appear generally cone-shaped as the angle offset of a plane of the planar flange increases from parallel. Any such configuration is considered within the scope of the invention.

As discussed above, the backer 16 can be formed of PVC, PET, etc., or any other suitable flexible plastic or polymeric sheet or film material and includes an inner surface 56 and an outer surface 58 (FIG. 4). Referring to FIGS. 2 and 3, the inner surface 56 of the backer 16 adjacent its peripheral edges 48, 50, 52, 54 defined by the planar flange 42 is fixedly secured (e.g., adhesively sealed, thermally welded, etc.) to the planar rim 32 of the front panel 14 to define a sealed region 68. The securement of the front panel 14 and backer 16 together create an enclosed cavity or article receiving pocket 18 (FIG. 4) in which the article of merchandise, for example, the toothbrush 12, is retained (FIG. 7). Of course, the printing may be applied to either the inner surface 56 or the outer surface 58 within the scope of the invention.

FIG. 4 depicts the blister package 10 in cross-section showing by example an amount of protrusion caused by the thermoforming of the front panel 14 and the backer 16. The first three-dimensional thermoformed structure 30 is protruded from the planar rim 32 a distance D1, and the second three-dimensional thermoformed structure 40 is shown protruding from the planar flange 42 a second distance D2. As can be seen in FIG. 4, the distance D2 is less than the distance D1, meaning that the backer 16 is not distorted to the same extent as the front panel. The second three-dimensional thermoformed structure 40 is not rectilinear or planar in cross-section, but rather is curved outward slightly convexly with a radius of curvature RC greater than the distance D2 that represents the projection distance of the second three-dimensional thermoformed structure from the planar flange 42. This minimizes any distortion of the second three-dimensional thermoformed structure and negates any distortion longitudinally parallel to the longitudinal axis 46. While not being limited to a particular theory, the examples illustrated in the figures show the radius of curvature RC at least about twice the distance D2 to minimize distortion while still providing a curved convex profile.

The second three-dimensional thermoformed structure 40 includes a cylindrical outline portion 44 that extends longitudinally along the thermoformed structure 40 preferably including the writings 20 shown by example in FIGS. 2, 3, and 6. As part of the second three-dimensional thermoformed structure 40, the cylindrical outline portion 44 is molded from the second planar plastic film 62 (FIG. 5) into its cylindrical shape as depicted in FIG. 6. The printing 20 is applied to the second planar plastic film 62 with an appearance free of distortion on the second planar plastic film. In other words, the printing is applied undistorted as if it were intended to be observed on a flat sheet.

After the second planar plastic film 62 is molded into the second three-dimensional thermoformed structure 40, the cylindrical outline portion still appears generally as depicted. During the thermoforming of the cylindrical outline portion 44, the portion is not deformed along or parallel to the longitudinal axis but is only deformed slightly transversely to the axis. This deformation keeps the cylindrical outline portion without longitudinal deformation, therefore minimizing any deformation of printing on the cylindrical outline portion 44. Beneficially, this molding of the cylindrical outline portion 44 does not distort the outline portion along linear segments 64 (FIG. 6) that are in parallel with the longitudinal axis 46. Accordingly, this molding only allows minimal distortion transverse to the longitudinal axis, thereby minimizing any distortion to the cylindrical outline portion or to any writing 20 applied to the cylindrical outline portion 44. This benefit means that the backer 16 is not distorted to the same extent as distortion of the front panel 14, and the writing 20 does not appear distorted on the thermoformed cylindrical outline portion 44. Accordingly, any writing 20 does not need to be pre-distorted prior to molding of the backer or final assembly of the package 10, which allows for clearer graphic and print designs and greater flexibility in applying the designs knowing that the printing applied to the second planar plastic film will look the same as the design viewed on the final assembled package 10.

While the front panel 14 and backer 16 have been described above as comprising a combination of materials including transparent, partially transparent, semi-transparent, etc., it is preferred that the blister package 10 include windows 60 of transparent material with or without printing for viewing the article within. For example, as can be seen in FIGS. 2, 3, 5, and 6, the backer 16 includes a window 60 of transparent material for allowing visual access to the head of the toothbrush 12. In combination with a window 66 of transparent material on the front panel 14 for visual access to the head and bristles of the toothbrush, a person now has a 360° view of the head of the toothbrush. The window 60 and other windows on the backer 16 help consumers see the backs of the toothbrushes or other features that traditionally are blocked from view prior to purchase of the toothbrush.

While the invention has been described in detail and with reference to specific examples thereof, it would be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope there. For example, the front panel 14 and backer 16 may be secured by a partial seal of the planar rim to the planar flange or by a frictional fit therebetween. Without further elaboration, the foregoing will so fully illustrate the invention that others may, by applying current or future knowledge, readily adapt the same for use under various conditions of service.

As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls. 

1. A blister package for housing an article, comprising: a front panel; a backer molded from a planar film and defining an outline portion laving a longitudinal axis and a convex curve cross-section; and a printing, on the outline portion; wherein the outline portion is linear along the longitudinal axis and has not been deformed along or parallel to the longitudinal axis but has only been deformed transversely to the axis, wherein the front panel and the backer are secured together to define a region for holding an article, and wherein the printing is legible on the backer.
 2. The blister package of claim 1, wherein the front panel further comprises a first three-dimensional structure and a planar rim; and the backer further comprises a planar flange and a second three-dimensional structure; the first three-dimensional structure protruding from the planar rim a first distance, the second three-dimensional structure protruding, from the planar flange a second distance, wherein the second distance is less than the first distance.
 3. The blister package of claim 1, wherein the outline portion is cone shaped.
 4. The blister package of claim 2, wherein a radius of curvature of the convex curve cross-section is greater than the second distance.
 5. The blister package of Claim 1, wherein the outline portion comprises a backer transparent section for visual access to the article.
 6. The blister package of claim 5, wherein the article is a toothbrush comprising: a head with an elongated handle; and bristles attached to the head, the backer transparent section allowing visual access to the head of the toothbrush.
 7. The blister package of claim 1, wherein the backer comprises an inner surface directed towards the article and an outer surface opposite the inner surface and directed away from the article, the printing being applied to the inner surface of the backer.
 8. The blister package of claim 1, wherein the backer comprises an inner surface directed towards the article and an outer surface opposite the inner surface and directed away from the article, the printing being applied to the outer surface of the backer.
 9. The blister package of claim 1, wherein the front panel further comprises a planar rim; and the backer further comprises a planar flange, the planar rim secured to the planar flange to define the region.
 10. The blister package of claim 1, wherein the outline portion extends across a width of the backer.
 11. A method for making a blister package for housing an article, comprising: a) providing a front panel; b) applying a printing to a planar film, the printing having an appearance free of distortion on the planar film; c) thermoforming the planar film into a backer to define an outline portion having a longitudinal axis and a convex curve cross-section, with the outline portion linear along the longitudinal axis, the printing thermoformed with the second planar film and maintaining a legible appearance regardless of distortion caused by the thermoforming; d) placing the article into one of the front panel or the backer; and e) sealing the front panel and the backer together with the article in between the front panel and the backer; wherein, during the thermoforming, the outline portion is not deformed along or parallel to the longitudinal axis but is only deformed transversely to the axis.
 12. The method of claim 11, wherein the outline portion is cylindrical.
 13. The method of claim 11, wherein the front panel further comprises a first three-dimensional structure and a planar rim; and the backer further comprises a planar flange and a second three-dimensional structure; the first three-dimensional structure protruding from the planar rim a first distance, the second three-dimensional structure protruding from the planar flange a second distance, wherein the second distance is less than the first distance.
 14. The method of claim 13, wherein the convex curve cross-section has a radius of curvature greater than the second distance.
 15. The method of claim 11, wherein the outline portion is cone shaped.
 16. A backer sealed to a front panel to form a blister package for housing an article, the front panel including a first three-dimensional thermoformed structure and a planar rim extending about the periphery of the first three-dimensional thermoformed structure, the first three-dimensional thermoformed structure molded from a first planar film and protruding from the planar rim to define an article receiving portion, the first three-dimensional thermoformed structure including a first transparent section for visual access to the article, the backer comprising: a second three-dimensional thermoformed structure; a planar flange extending about the periphery of the second three-dimensional thermoformed structure; and a printing, wherein the second three-dimensional thermoformed structure is molded from a second planar film and protrudes from the planar flange to define an outline portion having a longitudinal axis and a convex curve cross-section, wherein the outline portion is linear along the longitudinal axis and has not been deformed along or parallel to the longitudinal axis but has only been deformed transversely to the axis; the backer being sealed to the front panel by a bonding of the planar rim to the planar flange to define a sealed region, the first and second three-dimensional thermoformed structures cooperating to form an article receiving pocket for the article, the printing being on the outline portion and being legible on the backer.
 17. The backer of claim 16, the outline portion including a backer transparent section for visual access to the article.
 18. The backer of claim 17, wherein the article is a toothbrush comprising: a head with an elongated handle; and bristles attached to the head, wherein the backer transparent section allows visual access to the head of the toothbrush.
 19. The backer of claim 16, wherein the outline portion extends across a width of the backer between the planar flanges at opposite ends of the width.
 20. The backer of claim 16, wherein the first three-dimensional thermoformed structure protrudes from the planar rim a first distance, the second three-dimensional thermoformed structure protrudes from the planar flange a second distance less than the first distance.
 21. The backer of claim 16, wherein a radius of curvature of the convex curve cross-section is greater than the protrusion of the second three-dimensional thermoformed structure from the planar flange.
 22. The backer of claim 16, wherein the outline portion is cone shaped.
 23. The backer of claim 16, wherein the outline portion is cylindrical. 